Mold for making reflectors



Jan. 16, 1951 H. F. WILSON MOLD FOR MAKING REFLECTORS 2 Sheets-Sheet 1 Filed Oct. 1, 1946 C E X: fi w wm W5? E p gi ana D 30 o k F W, m M V Irv Jan. 16, 1951 H. F. WILSON MOLD FOR MAKING REFLECTORS 2 Sheets-Sheet 2 Filed Oct. 1, 1946 2 10 21911 F1917 E 15 F2 15 E] U 4H [MM/Q Ww Patented Jan. 16,?1951 1:11 i 1" ..1-

'- UNlT EDh'STATES ATENT OFFICE.

H Application October 1,1946, Serial No 700,442 I Q In Great Britain.Ju1y17., 1 939 Sectionli Public Law 690, August 8; 1946 Patent expires July 17, 1959 1 .1 The present invention relates to molds for the .When a number of such elements are assem manufacture of glass and other prismatic triple bled together in close formation to form a mould flectors. j g and the manufacture of triangular-face triple ll/Ioreparticularly the present invention aims at reflectors carried out in such mould the reflecihibrovingthose reflectors which comprise a plate 5 torsl'consist' of a series of tetrahedra conforming of glass or .mouldable synthetic plastic such as to a pattern which cannot be varied without reai t ificial resin, cellulose acetate or other suitdllcing the fi cy and with thedisadvantage L able. t i l 6 one f r f hi h are right that in practice a substantial portion of each tet- "gled or substantially right angled triplerefiecrahedron is non-reflecting as hereinbefore set rs forming tetrahedra' which reflect incident 10 forth. 1

back to the source and also at improving The non-reflecting areas in such reflectors have the; sectional moulds for forming such reflectors. been suppressed by cutting away each of th A known form of such refiectoris one in which three basevertices ofthe tetrahedra and by" the triple rflect'ors are grouped to form a reincorporation of similar additional triple reflecpeating geometric pattern consisting of recurring 151913 in the centre Ofeach group, but the mould cular groups of Six triple efle tors t groups hitherto used for a reflector of this character has .iepeating in close order and the plan View of beenof acomplicated nature, requiring an unduly 'ch group consisting of a six-sided figure which large .number of moulding elements.

a regular hexagon withkone side of thet i- .The present invention enables the non-reflectangular base or each six'triple reflectors formmg areas at the centre of each gro p 130 be e ing a side of the'- hexagon and the remaining: y upp essed and: replaced by additional triple as of the bases f t tri reflectors, h reflectors, without however necessitating so great "of which sides is common tothe base of an adan increase in the number of moulding elements joining triple reflector meeting at a common i t, 2 .-'as has been necessary in moulding the reflector gig-hat is the centre of the hexagon -ofjthe kind previously proposed-for minimising 11 is found that at the centre of each hexagom thlS l I I r oimmggroup. there is a dark area which reduces The imouldlaccolding 0 he. p esent invention the efliciency of-lithe'refiector as a whole. is comp sed as'hith'erto. of an aggregation: of In manufacturing triple reflectors'in which the d" elements d its p es form in -refiecting'surfaces are all three at right angles go' it'mollldso p, it Comprises S or substantially at right angles to each other it? "facet elementsflfor forming the central triple reis essential that the corresponding facet forming fictol' the group a Series O double facet eleunits in the mould be made with extreme optical s forming a hexagonal ap tur for these accuracy and it is of importance that such facet "elements anda marginal series of facet elements fo'rming units be produced economically and be Completing the elements for moulding the group. ap ofeasy and'rapid reconditioning a l a. 'Themargina'lseries may be single-facetele- :{A form of mould apparatus is described in Britm fi w ch may forma continuous regular hexf'ish Patent No. 269,760 and the facet forming agon. The mouldelements may be considered t mm nt' t i c ib d h v r d ll for as derived from elements of diamond section the the production of reflectors in accordance with -=marginalseries being half-diamond. section, i. e., {British Patents Nos.".233,002 and 270,790. Neveraiangular, thebaseof .the triangle being the *th'eless the present invention enables improved -maj'or. axis of-the diamond and forming one side "facet forming mould elements to be produced hav- Lofthe hexagona ou y; each of the three ing greater adaptability and-in turn-permitting central single-facetelements being also of such the manufacture of improved reflectors." '-half-diamond section but with the acute-angled -To produce triangular-face reflectors in accordvertic'es cut away toform a pentagon such that "ance with British 'Patent- 233,002 and Fig. 11: of ithethr'eeelements when assembled together form FBritish Patent 269,'760*thefacet forming elements 1a hexagon, and the intermediate elements being are out from"a i pnd'i half; diamondshape'd irof complete diamond section except that one of bar. In the case of diamond shaped elements'two 5O -theacute-angled verticesis cut off to enable these facets are cut-at one-end so that they intersect 2.)? stintermediateyelements .when assembledto forma along the longer-diagonal of the element each --central hexagonal aperture toreceive the three 'facet making an angle with the axis of the elecentral single-facet elements. ment of substantially 35-.degrees 16. minutes. The T .,Two or more ,of these groups may be arranged outer half diamond elements 'havebnly one facet '1111 any suitable disposition to form one reflector cut at the required anglel- :but: wheremore than one group is provided we 3 prefer that they should be so arranged that the base edges of the reflecting surfaces which form the outermost of the whole system form a single continuous hexagonal boundary and the mould for producing ,such a reflector compriszs .a central triad of jsingleefacet elements, a marginal series of single-facet elements which define a continuous hexagonal boundary and a multiplicity of intermediate dual-facet elements so arranged as to form the central openingtoreceive the aforesaid central triad and .to form .also :one or more series of openings around the central opening in which further similar triads are. arranged. This mould may be composed of elements of the form previously described together with dual-facet elements of a section derived from diamond section by removing both the opposite acute-angled vertices. The central hexagonal opening containing the central triad may be .formed of such latter elements only, and the openings containing the surrounding gtriads imay -.be-formed-by (a) such latter elements 112) 'fur- .th r dual-facet -elements of :the :Same :section and -.(c) anouter series of dual-facet elements of diamond section withone only of the acute-angled wvertices removed, thelatter elements mating with the half diamond single-facet marginal :elements :which form the hexagonal-boundary of the system of elements. Additional dual-facet elements may be provided for forming more than one circular .series of triads ofsingle-facet elements.

;A simple form-.oruteflectoriproduced Joya mould according to the present invention comprises a central triple reflector and :a :group f six surrounding triple reflectors, the base edges of :the :outer reflecting surfaces :of which form a continuous hexagon. Alternatively, :there may .be a series :of :groups of seven triple reflectors which each include one central triplereflectonsome of ethereflectors being common to more-than one :group and the base edges of the reflecting :sur- :faoes which form the outermost :of thesystem ionming a continuous hexagon. For example,

-theregmaybeam-central group and SiXaSURI-YOHHding groups of seven triple refiectoraitwotof each surrounding group being tetrahedra withonehase. wertex zonly removed, two tetrahedra having twjolease vertices removed and :the other two tetrahedra having each base vertex removed, the central-reflector .;of each group being also a tetrahedron having all three .base'vertices removed.

Where a series vof groupsare provided someqof the central reflectors are preferably orientate idifierently from others.

The reflector may be :formed with anannular rib surrounding the triple reflectors {and lying substantially flush with or extending above :the tops of them.

The invention :will be :more readily understood by reference to the accompanying drawings, :in which :two known :forms of reflector are :illustrated as well as reflectors and-moulds made by way of example according tothe invention.

Fig. '1 is a plan view of -:a known 'type ;of re- Jfiector whichgivesrise tothe aforesaid dark spots and Fig. 2 is aknownform of reflector designed to obviate this difiiculty but which *has led .to complications in the :mould construction. .Fig. 3 is a plan view of the simplest form 10f the reflector according to this invention and Fig. '4 ;-is a plan view of another form of reflector according to this invention. Fig.5 shows an alternative of the reflector according to Fig. 4. Fig. 6 *is a top plan'view and Fig. 7 an under plan :view of a mould for making' the reflector according "to Fig. 3, and Figs. 8 and 9 are similar plan views of a mould for producing the reflector according to Fig. 4. Fig. 10 shows a top view of a known mould element. Figs. 11 and 12 show in plan and 5 elevation respectively oneof .theimould elements used in themoulds according to Figs. '6 to 9; Figs. 13 and 14 are similar views of another mould element and Figs. 15 and 16 similar views of yet another mould element used in the said moulds. Figs. 17 and 18 are similar views of a further mould element which is used in the mould shown in Figs. 8 and 9. Fig. 19 is a sectional view through the sleeveand the companion component 'of the mould.

EI'he known form of reflector shown in Fig. 1 :showsrecurring circular groups of six triple reflectors in the form of tetrahedra each tetrahedron 1 having an equilateral triangular base and the inner base vertices of the six tetrahedra :meeting'at .a central @point. lAs-beforeetatedthis sform produces dark spaces approximately as indicated by the hatching in Fig. 1 of the drawings. These dark areas are eliminated gin-the known iform shown-in Fig. '2 where Ea-{central tripl flector 2 is provided within each lgrouprof, six triplereflectors 3, (each reflector being of 1a similar -form to :the 'tet-rahedron in Fig. ,1 .but having the "three base vertices cut away. The -.mo.u.ld :used for making %'this form of irefiector .;has con-- sisted-of threezseparate zsingle .ia'cet elements ,'for each refiector and this has complicated the con zstruction-of the.- mould.

:In the :zreflec-tor :shown in Fig. v3 .whi ch-1s :the :;product of this invention :there :iS one group- 0 :seven triple ireflectors which are containedzwithin a hexagonal iboundary. The central reflector '4 is surrounded :by fSiX reflectors :5, all the -vertices of the .tetrahedronfrom which the .central one .is iormed Ebeing cutaway but only the inner "base vertices of the tetrahedra from which the surroundingones are formed being 'removed sothatithe base edges of thevrouterrefiecting sur rfaces "6 ;of :all but the central reflector form ;a continuous heXa onaLboundary. More than one of these groups may :be provided in any suitable disposition "but Fig. A sh0ws:;a preferred: iorm where there :is .a series :of. groups of seven triple :reflectors around and completely overlap in ithe eouter members :of 'the central group. itl'iis "case the ;angles:0f :theghexagonal figure thatwould z-ncrmailly :be formed by thecentm ieroup are .initerrupted ;by the iintrusioneof portions of triple mefiectors wh ch-is consequence of :the rep tition and .overlan ing in the design illustrated form V the central-Jones ofathesurroundingland overlanping series of :reflectors each composed of seven. in order to facilitate the understanding of this iconstruction, the boundaries .of the members gqf "one of the surroundingggroupsmf seven reflectors has been {emph sised :in Fig. 4 and shading zhas been added, and it will be seen that two of each group, via, 13- and 29 ware tetrahedra with .one :base vertex only iremoved, two. via, ill] and Ir-l are tetrahedra .having two base -,ve rtices removed and the other two, viz., J2 and 1-3 are tetrahedra having each base vertex removed. The .central :reflectors M of the .groups are also tetrahedra :having all "three base 'vertices :removed.

Although the central reflectors of the various 7 groups :of seven may be -.-similarly "orientated :as

.shown in Fig. :4 it ;is preferred to give them =dif;- 'ferent orientations as, for example, is illustrated Fig. :5. Various changes 'oforientation can-obviously be obtained, :that illustrated in iel-1.5 75 being merely by way ofrexa'mple. I 1

tflectorsz; For producing reflectors as illustrated iiiniFigs. 3; .4 and 5 we find=it convenientt'oform ytheseimould; elements from agbasic diamond 'sef'c tion. In Fig, the basic. diamond is designated as A and the sections of the mould elements based thereon are shown in Figs..11 to 18 as B, C, D and i The mould elements B .andC are dual faceted and the mould elements D and E single-faceted. The elements C are hexagonal with two opposite sides longer than the remaining sides. The elements B are in the form of an irregular pentagon, as also are the mould elements E. The element B is formed by removing the acute angle of the diamond at a portion situate one third of: the length of the diagonal from one end thereof. Element C is formed by removing each acute angle of the diamond at a position situate one third of the length of the diagonal from the corresponding end-thereof, while the base of the pentagon of the" element E is made equal to the length of the base of the pentagon of element B and the longisides of the irregular hexagonof element C. the mould construction shown-in Figs. 6 and 7 the mould elements of the sections B, D and E are, employed. The six dual facet elements B when assembled in a cluster or ring like group of six as shown form a central hexagonal aperturefr'l5 which contains three singlefacet elements E and the six single-facet elements D mate with the six elements B and form an external hexagonal boundary. To obtain the best dark area eliminating effect the distance between opposite sides of the hexagonal aperture should be one third of the distance between opposite sides of such external hexagonal boundary. The size of the reflectors resulting from the triad of elements E which fill such apertures substantially eliminates the whole of the dark area at the centre of each hexagonal group indicated in Fig. 1.

By the use of further dual-faceted elements of section C and a greater number of elements B, D and E and by re-arrangement, one central group of seven reflectors may be surrounded by overllapping series pf additional groups, the whole sySJ-T tem being contained within a hexagonal boundary. This fgirmation is produced by the mould according to Figs. 8 and 9. The central group is in this construction formed of a central triad of elements E the hexagonal aperture for which is formed by six of the dual-faceted elements C. The latter co-operate with six further elements C, each adjoining two of the first series of elements C. With these elements C a surrounding series of the dual facet elements B may co-operate as shown to form a circular series of six further hexagonal apertures, each of which contains a triad of elements E while the mould is completed by a marginal series of twelve of the single facet elements D which define'the hexagonalboundary of the mould.

In the form just described only the central group is composed entirely of hexagonal elements but two or more of such groups may be assembled together in a recurring overlapping pattern of the desired size and shape. More than one circular series of central triads of elements E can be built up in this way.

To hold together an assembly of either or both types of the described elements within the main portion of the mould it is necessary to utilise a split sleeve "lficons-tructed. in two or more'parts rand-preferably; shaped to coincide .with the contour of such assembly and held within-appropriat'el retaini'ngmeans. The sleeved element 16 is preferably so constructed as illustrated in Fig. 19 that in erecting the mould elements the ;-latter ride proud. of the sleeve around them.

The companion ...portion 11 of the mould is so recessed that'whe'nboth portions of the mould are-brought together the-reflector is formed with .a-surrouhdingwall [8 of material which extends level with or above the top of the triple reflectors and serves to protect the latter from injurious contact.

The reflectors may be moulded with the apices downwards especially when moulded from glass as in this way slumping is avoided and a more accurate representation of the mould is thereby obtainable than if the reflectors are moulded with the apices upwards. On the other hand, when moulding the reflectors from synthetic resin it has been found advantageous to mould the reflectors in a vertical plane, pressure of the plastic or molten material being maintained for a sufficient time to ensure the proper formation of the reflector in the mould. I

The reflectors may be formed on the back of a convex lens as indicated by I! in Fig. 19.

Another disadvantage of the form of reflector shown in Fig. 1 is its having thick continuous break lines such as that indicated by X-X along which the risk of fracture is liable to occur, for example, during the moulding process. This disadvantage is obviated in a reflector produced by the mould herein described.

I claim:

1. A mold for making reflectors consisting of triangular triple-reflecting pyramids with rightangled vertices and with at least one of the base angles removed and comprising multiple elements in an outline of regular hexagonal form, and composed of a marginal series of elements formed with a single inclined mold facet and defining the outline, an inner ring of elements formed with two inclined mold facets and of a diamond cross section with both acute angles removed, and which produce a central hexagonal aperture, and in combination therewith further of these elements and a surrounding ring of elements which mate with said marginal elements and "are formed with two inclined mold facets and are of the same diamond cross section but with one only of the acute angles removed, thereby forming at least one series of hexagonal apertures on a hexagon around the central aperture, each of the said apertures being filled by a triad of single inclined facet mold elements which form a central pyramid within each of the overlapping clusters of six pyramids formed by the other elements.

2. A mold for making reflectors consisting of triangular triple-reflecting pyramids with rightangled vertices and with at least one of the base angles removed and comprising multiple elements in an outline of regular hexagonal form and consisting of a marginal series of elements formed with a single inclined mold facet and defining the outline, an inner ring of elements mating with said marginal series and formed with two inclined mold facets and of a diamond cross section with one acute angle removed and forming a central hexagonal aperture, said aperture being filled by a triad of single facet mold elements which form a central pyramid.

3. A mold according to claim 1, in which the I iriafisbi z'lement's finin me "said' hexagunail apex-- iare difierently :orientaltefi in the different 'za'px'ax'tures.

Number #941480 V PATENTS Great ataan $1. ean. 2811938 

